Method and system for exhaust particulate matter sensing

ABSTRACT

Methods and systems are provided sensing particulate matter by a particulate matter sensor positioned downstream of a diesel particulate filter in an exhaust system. In one example, a method may include increasing an inlet opening of the particulate matter sensor when an exhaust flow rate falls below a threshold to allow more particulates to enter the particulate matter sensor and further includes decreasing the inlet opening when the exhaust flow rate rises above the threshold to reduce the particulates entering the sensor. By adjusting the amount of particulates entering the sensor based on the exhaust rate, the rate of deposition of the sensor and hence the sensitivity of the sensor to the exhaust flow rate may be maintained at a desired level, and independent of the exhaust flow rate.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 14/835,270, entitled “METHOD AND SYSTEM FOR EXHAUSTPARTICULATE MATTER SENSING,” filed on Aug. 25, 2015, the entire contentsof which are hereby incorporated by reference for all purposes.

FIELD

The present description relates generally to the design and use ofresistive-type particle matter (PM) sensors in an exhaust gas flow.

BACKGROUND/SUMMARY

Diesel combustion exhaust is a regulated emission. Diesel particulatematter (PM), is the particulate component of diesel exhaust, whichincludes diesel soot and aerosols such as ash particulates, metallicabrasion particles, sulfates, and silicates. When released into theatmosphere, PMs can take the form of individual particles or chainaggregates, with most in the invisible sub-micrometer range of 100nanometers. Various technologies have been developed for identifying andfiltering out exhaust PMs before the exhaust is released to theatmosphere.

As an example, soot sensors, also known as PM sensors, may be used invehicles having internal combustion engines. A PM sensor may be locatedupstream and/or downstream of a diesel particulate filter (DPF), and maybe used to sense PM loading on the filter and diagnose operation of theDPF. Typically, the PM sensor may sense a particulate matter or sootload based on a correlation between a measured change in electricalconductivity (or resistivity) between a pair of electrodes placed on aplanar substrate surface of the sensor with the amount of PM depositedbetween the measuring electrodes. Specifically, the measuredconductivity provides a measure of soot accumulation. As such, thesensitivity of the PM sensors to measure PM in the exhaust may depend onthe exhaust flow rate, with increased exhaust flow rate leading toincreased PM sensor sensitivity and decreased exhaust flow rateresulting in decreased PM sensor sensitivity. With this increaseddependence on exhaust flow rate, the PM sensor capturing the PMs exitingthe DPF, may not truly reflect the DPF filtering capabilities.Furthermore, PM sensors may be prone to contamination from impingementof water droplets and/or larger particulates present in the exhaustgases, thus affecting the PM sensor sensitivity and leading to errors inthe output of the PM sensor.

One example PM sensor design is shown by Nelson in U.S. Pat. No.8,225,648B2. Therein, a PM sensor includes a flow redirector and abarrier positioned around a PM sensor element to filter out the largerparticulates from impinging the PM sensor element. The barrier thusserves to block larger particulates in the exhaust flow from impingingon the PM sensor element, thereby reducing PM sensor sensitivityfluctuations due to large particulates depositing on the PM sensorelement.

However, the inventors herein have recognized potential issues with suchan approach. As one example, the PM sensor sensitivity may continue todepend on the incoming exhaust flow rate. In one example, the issuesdescribed above may be partly addressed by a method for adjusting anamount of opening of an inlet to a particulate matter sensor positionedin an exhaust flow in response to an exhaust flow rate of the exhaustflow upstream of the particulate matter sensor, the particulate mattersensor element oriented with its major surface parallel to a directionof exhaust flow. In this way, the sensitivity of the particulate mattersensor may become independent of the exhaust flow rate and the PM sensoroutput may begin to measure the DPF filtering capabilities moreaccurately and reliably.

As one example, when the exhaust flow rate falls below a threshold, theamount of opening of the inlet of the PM sensor may be increased toallow more exhaust gas into the PM sensor for subsequent deposition on aPM sensor element positioned inside the PM sensor. When the exhaust flowrate rises above the threshold, the amount of inlet opening may bedecreased to reduce the exhaust gas entering the PM sensor. Herein, theincreasing and the decreasing of the amount of inlet opening may beregulated by adjusting (e.g., rotating) a movable flow controllerpositioned at the inlet. In this way, the amount of exhaust gas andthereby the amount of particulates getting deposited on the PM sensorelement positioned proximate to an outlet of the PM sensor may becomeindependent of the incoming exhaust flow rate, thereby measuring PMsexiting the DPF more accurately and reliably. Further, largerparticulates and/or water droplets may be trapped by the first flowredirector. The PM sensor element may be positioned parallel to thefirst flow redirector and a second flow redirector, with a narrowpassage located between the PM sensor element and the second flowredirector. Therefore, the PM sensor element may be protected fromimpingement of water droplets and larger particulates while attractingsmaller particulates to accumulate onto one of the major surfaces of thePM sensor element comprising electrodes. Overall, these characteristicsof the sensor may cause an output of the PM sensor to be more accurate,thereby increasing the accuracy of estimating particulate loading on aparticulate filter.

It should be understood that the summary above is provided to introducein simplified form a selection of concepts that are further described inthe detailed description. It is not meant to identify key or essentialfeatures of the claimed subject matter, the scope of which is defineduniquely by the claims that follow the detailed description.Furthermore, the claimed subject matter is not limited toimplementations that solve any disadvantages noted above or in any partof this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic diagram of an engine and an associatedparticulate matter (PM) sensor positioned in an exhaust flow.

FIGS. 2A-2B show magnified views of the PM sensor wherein an inletopening is increased or decreased based on an exhaust flow rate.

FIG. 2C shows another embodiment of the PM sensor depicted in FIGS. 2Aand 2B.

FIG. 2D shows a magnified view of a PM sensor element withinterdigitated electrodes.

FIG. 3 shows a flow chart depicting a method for adjusting the inletopening of the PM sensor based on the exhaust flow rate.

FIG. 4 shows a chart depicting a method for performing regeneration ofthe PM sensor.

FIG. 5 shows a flow chart depicting a method for diagnosing leaks in aparticulate filter positioned upstream of the PM sensor.

FIG. 6 shows an example relationship between the inlet opening of the PMsensor and a PM sensor loading based on the exhaust flow rate.

DETAILED DESCRIPTION

The following description relates to sensing particulate matter (PM) inan exhaust flow of an engine system, such as the engine system shown inFIG. 1. A PM sensor placed in an exhaust passage of the engine systemmay include a flow controller and a first flow redirector positionedproximate to an inlet of the PM sensor. An inlet opening of the PMsensor may be adjusted based on the exhaust flow rate by rotating theflow controller of the PM sensor, as shown in FIGS. 2A and 2B. The PMsensor comprises a PM sensor element, which may be oriented in aplurality of directions. A first direction is shown in the embodimentsof FIGS. 2A and 2B. A second direction is shown in the embodiment ofFIG. 2C. A top view of the PM sensor with an example interdigitatedelectrode is shown in FIG. 2D. A controller may be configured to performa control routine, such as the routine of FIG. 3 to adjust an amount ofopening of the inlet opening of the PM sensor based on the exhaust flowrate. In addition, the controller may intermittently clean the PM sensor(as shown in the method presented at FIG. 4) to enable continued PMdetection and perform diagnostics on a particulate filter positionedupstream of the PM sensor based on an output of the PM sensor (as shownin the method presented at FIG. 5). An example relation between the PMsensor inlet opening and the PM sensor loading based on the exhaust flowrate is depicted with reference to FIG. 6. In this way, by adjusting theinlet opening based on the exhaust flow rate, the PM sensor sensitivitymay become independent of the incoming exhaust flow rate. Further,larger particulates and/or water droplets may be trapped by the firstflow redirector. Therefore, the PM sensor element may be protected fromimpingement of water droplets and larger particulates. Overall, thefunctioning of the PM sensor to estimate the filtering capabilities ofthe DPF (and thereby to detect DPF leaks) may be improved and exhaustemissions compliance may be improved as PMs in the exhaust may bedetected more accurately and reliably.

FIG. 1 shows a schematic depiction of a vehicle system 6. The vehiclesystem 6 includes an engine system 8. The engine system 8 may include anengine 10 having a plurality of cylinders 30. Engine 10 includes anengine intake 23 and an engine exhaust 25. Engine intake 23 includes athrottle 62 fluidly coupled to the engine intake manifold 44 via anintake passage 42. The engine exhaust 25 includes an exhaust manifold 48eventually leading to an exhaust passage 35 that routes exhaust gas tothe atmosphere. Throttle 62 may be located in intake passage 42downstream of a boosting device, such as a turbocharger (not shown), andupstream of an after-cooler (not shown). When included, the after-coolermay be configured to reduce the temperature of intake air compressed bythe boosting device.

Engine exhaust 25 may include one or more emission control devices 70,which may be mounted in a close-coupled position in the exhaust. One ormore emission control devices may include a three-way catalyst, lean NOxfilter, SCR catalyst, etc. Engine exhaust 25 may also include dieselparticulate filter (DPF) 102, which temporarily filters PMs fromentering gases, positioned upstream of emission control device 70. Inone example, as depicted, DPF 102 is a diesel particulate matterretaining system. DPF 102 may have a monolith structure made of, forexample, cordierite or silicon carbide, with a plurality of channelsinside for filtering particulate matter from diesel exhaust gas.Tailpipe exhaust gas that has been filtered of PMs, following passagethrough DPF 102, may be measured in a PM sensor 106 and furtherprocessed in emission control device 70 and expelled to the atmospherevia exhaust passage 35. In the depicted example, PM sensor 106 is aresistive sensor that estimates the filtering efficiency of the DPF 102based on a change in conductivity measured across the electrodes of thePM sensor. A schematic view 200 of the PM sensor 106 is shown at FIG. 2,as described in further detail below.

The vehicle system 6 may further include control system 14. Controlsystem 14 is shown receiving information from a plurality of sensors 16(various examples of which are described herein) and sending controlsignals to a plurality of actuators 81 (various examples of which aredescribed herein). As one example, sensors 16 may include exhaust flowrate sensor 126 configured to measure a flow rate of exhaust gas throughthe exhaust passage 35, exhaust gas sensor (located in exhaust manifold48), temperature sensor 128, pressure sensor 129 (located downstream ofemission control device 70), and PM sensor 106. Other sensors such asadditional pressure, temperature, air/fuel ratio, exhaust flow rate andcomposition sensors may be coupled to various locations in the vehiclesystem 6. As another example, the actuators may include fuel injectors66, throttle 62, DPF valves that control filter regeneration (notshown), a motor actuator controlling PM sensor opening (e.g., controlleropening of a valve or plate in an inlet of the PM sensor), etc. Thecontrol system 14 may include a controller 12. The controller 12 may beconfigured with computer readable instructions stored on non-transitorymemory. The controller 12 receives signals from the various sensors ofFIG. 1, processes the signals, and employs the various actuators of FIG.1 to adjust engine operation based on the received signals andinstructions stored on a memory of the controller. Example routines aredescribed herein with reference to FIGS. 3-5.

Turning now to FIGS. 2A-2B, schematic views of a first embodiment of aparticulate matter (PM) sensor 201 (such as PM sensor 106 of FIG. 1) isshown. FIG. 2A shows a first schematic 200 of the PM sensor 201 with aflow controller 238 in a first configuration and FIG. 2B shows a secondschematic 260 of the PM sensor 201 with the flow controller 238 in asecond configuration. The PM sensor 201 may be configured to measure PMmass and/or concentration in the exhaust gas, and as such, may becoupled to an exhaust passage (e.g., such as the exhaust passage 35shown in FIG. 1), upstream or downstream of a diesel particulate filter(such as DPF 102 shown in FIG. 1).

As shown in FIGS. 2A-2B, the PM sensor 106 is disposed inside exhaustpassage 235 with exhaust gases flowing from downstream of a dieselparticulate filter towards an exhaust tailpipe, as indicated by arrows246. PM sensor 106 includes a protection tube 250 that may serve toprotect a PM sensor element 254 of the PM sensor 201 housed within andmay additionally serve to redirect exhaust gas flow over the PM sensorelement 254 as explained below.

The PM sensor element 254 includes a pair of planar interdigitatedelectrodes 220 forming a “comb” structure. These electrodes may betypically manufactured from metals such as platinum, gold, osmium,rhodium, iridium, ruthenium, aluminum, titanium, zirconium, and thelike, as well as, oxides, cements, alloys and combination comprising atleast one of the foregoing metals. The electrodes 220 are formed on asubstrate 216 that is typically manufactured from highly electricallyinsulating materials. Possible electrically insulating materials mayinclude oxides such as alumina, zirconia, yttria, lanthanum oxide,silica, and combinations comprising at least one of the foregoing, orany like material capable of inhibiting electrical communication andproviding physical protection for the pair of interdigitated electrodes.The spacing between the comb “tines” of the two electrodes may typicallybe in the range from 10 micrometers to 100 micrometers with thelinewidth of each individual “tine” being about the same value, althoughthe latter is not necessary. As shown in FIGS. 2A-2B, the interdigitatedelectrodes 220 extend along and cover a portion of the substrate 216.

A positive electrode of the pair of interdigitated electrodes 220 isconnected with connecting wires 224 to a positive terminal of a voltagesource 228 of an electric circuit 258. A negative electrode of the pairof interdigitated electrodes 220 is connected to a measurement device226 via a connecting wire 222, and further connected to a negativeterminal of the voltage source 228 of the electric circuit 258. Theinterconnecting wires 222 and 224, the voltage source 228 and themeasurement device 226 are part of the electric circuit 258 and arehoused outside the exhaust passage 35 (as one example, <1 meter away).Further, the voltage source 228 and the measurement device of theelectric circuit 258 may be controlled by a controller, such ascontroller 12 of FIG. 1, so that particulate matter collected at the PMsensor may be used for diagnosing leaks in the DPF, for example. Assuch, the measurement device 226 may be any device capable of reading aresistance change across the electrodes, such as a voltmeter. As PM orsoot particles get deposited between the electrodes 220, the resistancebetween the electrode pair may start to decrease, which is indicated bya decrease in the voltage measured by the measurement device 226. Thecontroller 12 may be able to determine the resistance between theelectrodes 220 as a function of voltage measured by the measurementdevice 226 and infer a corresponding PM or soot load on the planarelectrodes 220 of the PM sensor 201. By monitoring the load on the PMsensor 201, the exhaust soot load downstream of the DPF may bedetermined, and thereby used to diagnose and monitor the health andfunctioning of the DPF.

The PM sensor element 254 also includes a heating element 218 that is beintegrated into the sensor substrate 216. In alternate embodiments, thePM sensor element 254 may not include a heating element 218. The heatingelement 218 may comprise, but is not limited to, a temperature sensor,and a heater. Possible materials for the heater and the temperaturesensor forming the heating element 218 may include platinum, gold,palladium, and the like; and alloys, oxides, and combinations comprisingat least one of the foregoing materials, with platinum/alumina,platinum/palladium, platinum, and palladium. The heating element 218 maybe used for regenerating the PM sensor element 254. Specifically, duringconditions when the particulate matter load or soot load of the PMsensor element 254 is higher than a threshold, heating element 218 maybe operated to burn accumulated soot particles from the surface ofsensor. During PM sensor regeneration, the controller 12 may provide avoltage to a voltage source 230, which is needed for operating theheating element 218. In addition, the controller may close the switch232 for a threshold time to apply the voltage via the voltage source 230to the heating element 218 in order to raise the temperature of theheating element 218. Subsequently, when the sensor electrodes aresufficiently clean, the controller may open the switch 232 to stopheating the heating element 218. By intermittently regenerating the PMsensor 201, it may be returned to a condition (e.g., unloaded or onlypartially loaded condition) more suitable for collecting exhaust soot.In addition, accurate information pertaining to the exhaust soot levelmay be inferred from the sensor regeneration and this information may beused by the controller for diagnosing leaks in the particulate filter.The sensitivity of the PM sensor may be affected by large particulatesand/or water droplets getting deposited on the PM sensor element 254. Inaddition, the sensitivity of the PM sensor element 254 may furtherdepend on the exhaust flow rate. Higher sensitivity is typicallyobserved at higher exhaust flow, while lower sensitivity occurs at lowerexhaust flow. It may be possible to filter out larger particulates andwater droplets and obtain a flow independent PM sensor by using a designfor the protection tube 250, as described below.

The protection tube 250 may be a hollow cylindrical tube with anupstream tube wall 208 (e.g., upstream facing wall), a downstream tubewall 206 (e.g., downstream facing wall), and a top surface 212. Theupstream tube wall 208 may be closer to a DPF than the downstream tubewall 206 when positioned in an exhaust passage such as the exhaustpassage 235 shown in FIG. 1 where the DPF is positioned upstream of thePM sensor. Further, exhaust gases flowing through the exhaust passage135 may first contact the upstream tube wall 208 of the PM sensor. Thetop surface 212 may further include an inset portion 252 through whichthe PM sensor element 254 and its accompanying electrical connectionsmay be inserted into the protection tube 250, and further be sealed toprotect the PM sensor element 254 housed within the PM sensor 201. Theprotection tube 250 may be mounted onto the exhaust passage 35 viasensor boss 202 and 204 such that the central axis of the protectiontube 250 is along the Y-axis, and also such that the central axis of theprotection tube 250 is perpendicular to the exhaust passage 35 and theexhaust flow through the exhaust passage. As shown in FIGS. 2A-2B, theprotection tube 250 extends into a portion of the exhaust passage 35.The depth to which the protection tube extends into the exhaust passagemay depend on exhaust pipe diameter. In some examples, the protectiontube may extend to about one third to two third of the exhaust pipediameter. The bottom of the protection tube 250 may be cut at an angle(dashed line 210) forming an angled inlet that introduces exhaust flowinto the PM sensor 201. Herein, the angled bottom portion (210) of thePM sensor 201 may be formed by cutting the protection tube 250 at adiagonal, for example a 30° or 45° angle with respect to the horizontalX-axis, as shown in FIG. 2A. As such, the length of the upstream tubewall 208 is smaller than the length of the downstream tube wall 206.Thus, the angled bottom portion 210 of the protection tube 250 serves asan inlet to the PM sensor 201, and henceforth referred to as inlet 210.The PM sensor 201 also includes an outlet 214 positioned a distance awayfrom the inlet of the PM sensor 201. The outlet 214 may be a single holeor plurality of holes positioned along one or more of a back wall and afront wall of the protection tube 250 (not shown). As such, the frontwall and the back surface of the protection tube 250 may be surfaces ofthe hollow cylindrical protection tube 250 that are different from theupstream tube wall 208 and the downstream tube wall 206. While theoutlet 214 is shown as an elliptical hole in FIG. 2A, other shapes andsizes of the outlet 214 may also be used without departing from thescope of this disclosure.

The protection tube 250 further includes a first flow redirector 234 anda second flow redirector 236 mounted onto the inner wall (e.g., insidesurface) of the hollow cylindrical protection tube 250. The first andthe second flow redirectors, 234 and 236, may be made from portions of acircular plate and positioned on opposite sides of the interior of theprotection tube 250 relative to the central axis of the protection tube250. For example, the first flow redirector 234 may be mounted on theinner surface of the protection tube corresponding to the downstreamtube wall 206 of the protection tube 250 and the second flow redirector236 may be mounted on the inner surface of the protection tubecorresponding to the upstream tube wall 208 of the protection tube 250.Herein, the first flow redirector 234 is positioned proximate to theinlet 210 of the PM sensor 201, and the second flow redirector ispositioned proximate to the outlet 214 of the PM sensor 201. Thus, thefirst flow redirector 234 is closer to the inlet 210 than the secondflow redirector 236 and the second flow redirector 236 is closer to theoutlet 214 than the first flow redirector 234. The sensing portion ofthe PM sensor element 254 (e.g., the electrodes 220) may be insertedinto the protection tube 250 such that the sensing portion of the sensorelement 254 is closer to the second flow redirector than the first flowredirector. Furthermore, the PM sensor element 254 is closer to theoutlet 214 than the inlet 210.

One end of the second flow redirector 236 may be attached to the innersurface of the upstream tube wall 208 of the protection tube 250, whilethe opposite end of the second flow redirector 236 may be unattached tothe wall of the protection tube 250. For example, the opposite,unattached end of the second flow redirector is spaced away from and notin contact with the inner wall of the protection tube 250. Herein, theunattached end of the second flow redirector 236 may be closer to theoutlet 214 of the PM sensor 201 than the inlet 210 and positioned adistance away from the unattached end of the first flow redirector 234.Furthermore, the sensing portion of the PM sensor element 254 may becloser to the unattached end of the second flow redirector 236, furtherseparated from each of the attached end of the second flow redirector236 and the inner surface of the downstream tube wall 208. Furtherstill, the sensing portion of the PM sensor element 254 may be separatedat a distance from the unattached end of the second flow redirector 236,thereby forming a gap between the unattached end of second flowredirector and the sensing portion of the PM sensor element 254. Thusthe unattached end of the second flow redirector 236 and the sensingportion of the PM sensor element 254 are each closer to one another thanthe first flow redirector 234 and also closer the outlet 214 than theinlet 210 of the PM sensor 201, for example. The second flow redirector236 extends across a portion of the protection tube 250, however, theunattached end of the second flow redirector 236 is spaced away from theinner surface of the protection tube 250.

Similarly, one end of the first flow redirector 234 may be attached tothe inner surface of the downstream tube wall 206 of the protection tube250, while the opposite end of the first flow redirector 234 may beunattached to the wall of the protection tube 250. For example, theopposite, unattached end of the first flow redirector is spaced awayfrom and not in contact with the inner wall of the protection tube 250.Herein, the unattached end of the first flow redirector 234 may becloser to the inlet 210 of the PM sensor 201 than the outlet 214 andpositioned a distance away from the unattached end of the second flowredirector 236. In some embodiments, the length of the flow redirectors234 and 236, determined as the distance the flow redirectors extend intothe hollow space inside the protection tube 250 along the X-axis, may beequal. In other embodiments, the lengths of the flow redirectors 234 and236 may be unequal, wherein one of the flow redirectors (first/second)may extend longer into the hollow space of the protection tube than theother flow redirector (second/first).

Further, the unattached ends of each of the first and second flowredirectors 234 and 236 form openings for exhaust gas flow to pass. Asshown in FIGS. 2A-2B, the first opening formed between the unattachedend of the first flow redirector 234 and the second opening formedbetween the unattached end of the second flow redirector 236 are onopposite sides of the protection tube 250 relative to the central axis.Further, the first flow redirector 234 extends from the inner wall ofthe protection tube 250 in a first direction and the second flowredirector 236 extends from the inner wall of the protection tube 250 ina second direction, opposite the first direction.

The first flow redirector 234 is separated from the second flowredirector 236 by a space/distance. The PM sensor element 254 ispositioned between the first flow redirector 234 and the second flowredirector 236 such that the sensing portion of the PM sensor elementextends into the space between the first flow redirector 234 and thesecond flow redirector 236. Herein, the sensing portion of the PM sensorelement 254 is directed towards a direction opposite to the incomingexhaust flow 246, for example. The electrodes 220 of the PM sensorelement 254 are facing towards the incoming exhaust flow 246 (towardsthe upstream tube wall 208, for example). It will be appreciated bysomeone skilled in the art that the sensing portion of the PM sensorelement may be oriented in other directions, such as the direction shownin FIG. 2C.

Typically, PM sensors suffer from issues of PM sensor sensitivitydependence on the exhaust flow rate through the passage in which thesensor is coupled whereby the PM sensor sensitivity increases whenexhaust flow rate is higher than a threshold, and subsequently decreaseswhen the exhaust flow rate is lower than the threshold. It may bepossible to adjust the opening of the PM sensor as described below toincrease or decrease the PM sensor opening based on when the exhaustflow rate is higher or lower than a threshold, thereby reducing thesensitivity dependence on the exhaust flow rate.

Returning to FIGS. 2A-2B, the protection tube 250 also includes a flowcontroller 238 positioned proximate to one or more of the inlet 210 andthe first flow redirector 234. A size of the inlet opening into aninterior of the PM sensor 201 is controlled by the position of the flowcontroller with respect to the first flow redirector, for example. Assuch, the size of the inlet opening (or the amount of opening of theinlet) of the PM sensor 201 controls an amount of exhaust air flowthrough the inlet 210 and into the interior of the PM sensor. When theamount of opening of the inlet is increased, then more exhaust gas flowsinto the PM sensor, and when the amount of opening of the inlet of thePM sensor is decreased, exhaust gas flow into the PM sensor isrestricted. The increasing and the decreasing of the PM sensor inletopening may be enabled by moving and/or rotating the flow controller 238as described below. As such, the increasing and decreasing of the inletopening results in a more consistent rate of exhaust flow to the sensingelement 254. As a result, the sensitivity of the PM sensor may bemaintained at a more consistent level and the sensor dependency on flowrate may be decreased. In this way, the PM sensor sensitivity dependenceon the exhaust flow rate may be reduced.

As shown in FIGS. 2A-2B, the flow controller 238 is a movable platecoupled to the upstream tube wall 208 of the protection tube 250 via ahinge 240 at one end of the movable plate, and is further unattached oruncoupled to any additional structure at the opposite end of the movableplate. In alternate embodiments, the flow controller 238 may be aflapper valve or another type of adjustable element adapted to adjust anamount of opening of the inlet 210.

The unattached end of the movable plate is proximate to the unattachedend of the first flow redirector 234. A distance separating theunattached end of the first flow redirector 234 and the unattached endof the movable plate of the flow controller 238 creates a gap, or aninlet opening 248, between the flow controller 238 and the first flowredirector 234. When the flow controller 238 is moved closer to thefirst flow redirector 234, thereby decreasing the distance separatingthe unattached end of the first flow redirector 234 and the unattachedend of the movable plate of the flow controller 238, the inlet opening248 is decreased. When the flow controller 238 is moved in the oppositedirection, away from the first flow redirector 234, the inlet opening248 of the PM sensor is increased. The hinge 240 connecting one end ofthe flow controller 238 to the wall of the protection tube 250 ispositioned on the upstream side of the PM sensor 201, and coupled to theupstream tube wall 208 of the protection tube 250. The flow controller238 is pivoted to rotate about an axis of the hinge 240. As shown inFIGS. 2A-2B, the hinge 240 is actuated by a motor actuator 256 and themotor actuator 256 may be an electric motor actuator, for example. Inalternate embodiments, the actuator for actuating the flow controller238 may be an alternate type of actuator in electronic communicationwith the controller.

In some embodiments, the first flow redirector 234 may be attached tothe upstream tube wall 208, the second flow redirector may be attachedto the downstream tube wall 206 and the flow controller may be attachedto the downstream tube wall 206. In such an embodiment, the PM sensorelement 254 may face on the same direction as the arrow indicated forincoming exhaust flow 246. In some example embodiments, plurality offlow redirectors may be positioned along the inner surface of theprotection tube to guide the particulates towards the PM sensor element254.

Controller 12 may send signals for adjusting the flow controllerposition to motor actuator 256. These signals may include commands torotate the flow controller towards and away from the first flowredirector 234. For example, when the exhaust flow rate is higher than athreshold rate, the controller 12 may send signals to the motor actuator256, which in turn actuates the hinge, thereby rotating the flowcontroller 238 in a first direction that decreases the inlet opening (asshown by the position of the flow controller 238 and smaller inletopening 248 in FIG. 2B, as discussed further below). As an example,controller 12 may send signals to the motor actuator 256 to rotate theflow controller 30° in the anti-clockwise direction about the X-axis,when the exhaust flow rate is higher than the threshold. As such, thedegree of opening may depend on the exhaust flow rate. However, when theexhaust flow rate falls below the threshold, then the controller maysend signals to the motor actuator 256, to rotate the flow controller ina second direction, thereby increasing the inlet opening (as shown bythe larger inlet opening 248 in FIG. 2A). As such, the second directionmay be opposite to the first direction and rotating the flow controllermay involve actuating the hinge thereby moving the flow controller inthe second direction. As an example, controller 12 may command the motoractuator 256 to rotate the flow controller 30° in the clockwisedirection about the X-axis when the exhaust flow rate falls below thethreshold. In this way, the inlet opening 248 of the PM sensor 201 maybe increased or decreased depending on whether the exhaust flow rate islower or higher than the threshold by active adjustments made to theposition of the flow controller 238. Additionally or alternatively, thecontroller 12 may adjust the position of the flow controller 238 as afunction of the exhaust flow rate. Thus, as the exhaust flow rateincreases, the controller 12 may rotate the flow controller 238 closerto the first flow redirector 234, thereby decreasing the inlet opening248. In this way, the flow controller 238 may be adjusted into aplurality of positions based on the exhaust flow rate.

In some embodiments, the flow controller 238 may be passively adjustedbased on the pressure exerted on an outer face of the movable plate ofthe flow controller 238 by the incoming exhaust gas. Herein, the flowcontroller 238 may be coupled to the inside surface of the upstream tubewall 208 via a spring hinge capable of axial rotation. When the exhaustflow rate is higher than the threshold, the pressure exerted by theincoming exhaust gas on the flow controller may be higher, and thatwould cause the spring hinge to rotate in a first direction (for exampleanti-clockwise direction), thereby moving the flow controller 238 closerto the first flow redirector 234 and decreasing the inlet opening 248.In this embodiment, the degree or the amount by which the flowcontroller 238 rotates or moves may depend on the spring constant of thespring hinge, and the pressure exerted by the incoming exhaust gas.However, when the exhaust flow rate falls below a threshold, thepressure exerted by the incoming exhaust gas on the flow controller maybe lower causing the spring hinge to rotate in a second direction,opposite to the first direction (for example, in clockwise direction),thereby moving the flow controller 238 away from the first flow directorand increasing the inlet opening 248. Again, the degree or the amount bywhich the flow controller 238 rotates or moves may depend on the springconstant of the spring hinge, and the pressure exerted by the incomingexhaust gas. In some examples, when the exhaust flow rate is lower thanthe threshold, the spring hinge may in its equilibrium position, therebythe inlet opening may be maximally opened. In this example, the flowcontroller moves passively and is not controlled by the controller.

By moving the flow controller position based on the exhaust flow rate,it may be possible to adjust the inlet opening of the PM sensor so thatthe amount of exhaust gas entering the PM sensor and thus the rate atwhich particulates get deposited on the PM sensor element 254 is nearconstant (e.g., maintained at a relatively constant level). As such, theflow controller may be moved actively by actuating the motor actuator256, or passively by the pressure exerted on the flow controller by theincoming exhaust flow. Regardless of whether the flow controlleradjustment is active or passive, the rate of deposition of particulateson the PM sensor element is independent of the exhaust flow rate,thereby making the PM sensor sensitivity independent of the incomingexhaust flow rate. This is elucidated further with respect to theexhaust flow paths inside the PM sensor 201.

Incoming exhaust flow 246 (also called incoming exhaust or incomingexhaust gas) refers to exhaust upstream of the PM sensor 201, whichenters the inlet 210 of the PM sensor 201. As such, the exhaust flow 246is the exhaust gas that exits the DPF, for example. Due to the presenceof the flow controller 238 proximate to the inlet 210 of the PM sensor201, a portion of the incoming exhaust flow 246 gets blocked, and only aremaining portion of the incoming exhaust flow 246, indicated as exhaustflow 247 flows into the PM sensor inlet opening 248. The exhaust flow247 flowing into the inlet opening 248 flows into the PM sensor inletopening 248 via the space between the unattached end of the flowcontroller 238 and the downstream tube wall 206, for example. Theexhaust flow 247 may include a portion of the incoming exhaust flow 246.Based on the flow rate of the incoming exhaust 246, the flow controller238 may be rotated either actively via motor actuator 256 or passivelyvia spring hinge, as described earlier. When the exhaust flow rate ofthe incoming exhaust 246 is lower than the threshold, then the flowcontroller 238 may be adjusted to increase the inlet opening 248 asshown in view 200 of FIG. 2A. As such, the adjustment of the flowcontroller 238 includes moving the flow controller 238 in a first (e.g.,clockwise) direction away from the first flow redirector 234, therebyincreasing the inlet opening 248. The exhaust flow 247 enters the PMsensor 201 through the inlet opening 248. The first flow redirector 234then traps a first set of particulates in the exhaust flow 247 at thebottom surface of the first flow redirector 234 that faces the inlet 210of the PM sensor 201. The first set of particulates include particulatesin the exhaust flow 247 that are larger than a threshold size. Thelarger particulates and/or water droplets 242 that get trapped at thefirst flow redirector 234 may thus exit the PM sensor 201 via inlet 210,thereby reducing the amount of larger particulates depositing on the PMsensor element 254. In this way, the PM sensor element may be protectedfrom impingement of water droplets and larger particulates and the PMsensor may be made more reliable.

The first flow redirector 234 further guides a portion of the exhaustflow (249) from the inlet opening 248 to one or more of the second flowredirector 236 and the PM sensor element 254. The exhaust flow 249 mayinclude a portion of the incoming exhaust flow 246 (and a portion ofexhaust flow 247) that is guided towards the PM sensor element 254 ofthe PM sensor 201 by the first flow redirector 234. For example, thefirst flow redirector 234 may guide a second set of particulates 244 inthe exhaust flow 249 towards the PM sensor element 254, where they aresubsequently deposited. As such, the second set of particulates 244 maybe smaller in size compared to the first set of particulates 242 thatwere previously blocked at the first flow redirector 234, for example.

When the exhaust flow rate of the incoming exhaust 246 is higher thanthe threshold, then the flow controller 238 may be adjusted to decreasethe inlet opening 248, as shown in view 250 of FIG. 2B. As such, theadjustment of the flow controller 238 includes moving the flowcontroller 238 in a second (e.g., anti-clockwise) direction towards thefirst flow redirector 234, thereby decreasing the inlet opening 248. Theexhaust flow 247 enters the PM sensor 201 through a restricted inletopening 248 (FIG. 2B). As explained with regard to FIG. 2A, the firstflow redirector 234 traps a first set of particulates in the exhaustflow 247 at the bottom surface of the first flow redirector 234 thatfaces the inlet 210 of the PM sensor 201. Since the inlet opening isdecreased, the amount of exhaust gas 249 entering the PM sensor inletopening 248 is reduced.

The first flow redirector 234 further guides a portion of the exhaustflow 249 from the inlet opening 248 to one or more of the second flowredirector 236 and the PM sensor element 254 (see FIGS. 2A and 2B). Theexhaust flow 249 refers to a portion of the incoming exhaust flow 246(and also a portion of exhaust flow 247) that is guided towards the PMsensor element 254 of the PM sensor 201 by the first flow redirector234. As such, the exhaust flow 249 flowing through a larger opening 248in FIG. 2A may be larger than the exhaust flow 249 flowing through therestricted opening 248 in FIG. 2B. However in both views 200 and 250,the first flow redirector 234 may guide a second set of particulates 244towards the PM sensor element 254, where they are subsequentlydeposited. The second flow redirector 236 positioned at a level higherthan the sensing portion of the PM sensor element 254 further guides thesecond set of particulates 244 towards the PM sensor element 254. Thesecond flow redirector 236 may further guide the exhaust flow to thesensing element 254 before it escapes out of the PM sensor 201. As such,the second set of particulates 244 may be smaller in size compared tothe first set of particulates 242 that were previously blocked at thefirst flow redirector 234, for example. However by adjusting the inletopening of the PM sensor, the amount of exhaust gas entering the PMsensor may be adjusted in order for the particulate deposition rate onthe PM sensor element 254 to be remain constant. When the second set ofparticulates 244 are deposited on the PM sensor element 254,particularly on the electrodes 220 on the sensor substrate 216, theresistance as measured in the electric circuit 258 by the measurementdevice 226 decreases. The controller 12 may compute a soot load on thePM sensor electrodes 220 based on the resistance measured by themeasurement device (such as measurement device 226 of FIGS. 2A and 2B,for example). When the soot load reaches a threshold load, the PM sensorelectrodes 220 may be regenerated to clean the electrode surface off anyparticulates deposited on them. By monitoring the deposition rate and/orthe time to regeneration of the PM sensor, it may be possible todiagnose leaks in the particulate filter located upstream of the PMsensor. As such, the second flow redirector 236 further guides a portionof the exhaust flow 251 through the outlet 214 of the PM sensor 201.Thus, exhaust flow 251 may be a portion of the incoming exhaust 246 thatexits the PM sensor electrode via the outlet 214.

FIGS. 2A and 2B show example configurations with relative positioning ofthe various components. If shown directly contacting each other, ordirectly coupled, then such elements may be referred to as directlycontacting or directly coupled, respectively, at least in one example.Similarly, elements shown contiguous or adjacent to one another may becontiguous or adjacent to each other, respectively, at least in oneexample. As an example, components laying in face-sharing contact witheach other may be referred to as in face-sharing contact. As anotherexample, elements positioned apart from each other with only a spacethere-between and no other components may be referred to as such, in atleast one example.

Thus, the exhaust flow to a PM sensor element positioned inside the PMsensor, where the PM sensor is positioned in an exhaust flow passage,may be increased responsive to an exhaust flow rate of exhaust flow inthe exhaust flow passage being lower than a threshold. The exhaust flowto the PM sensor may further be decreased responsive to the exhaust flowrate being higher than the threshold. Increasing the exhaust flowincludes rotating a flow controller located proximate to an inletopening of the PM sensor in a first direction and furthermore decreasingthe exhaust flow includes rotating the flow rate controller in a seconddirection, opposite the first direction. Rotating the flow controller inthe first direction further includes moving the flow rate controlleraway from a first flow plate or first flow redirector positioned at ornear the inlet opening of the PM sensor, and rotating the flowcontroller in the second direction further includes moving the flow ratecontroller towards the first flow plate of the PM sensor assembly. Inone example, the rotation of the flow controller may be controlled by acontroller and a motor actuator which may be actuated by the controllerto rotate the hinge coupled to the flow controller. In other examples,the flow controller rotation may occur passively, without any signalsfrom the controller. Herein, the pressure exerted by the incomingexhaust may rotate the flow controller coupled to the PM sensor viaspring hinges, for example. The PM sensor may further include a secondflow plate or second flow redirector located proximate to an outlet ofthe PM sensor, and the second flow plate may be separated from the firstflow plate by a distance. The function of the first flow redirector mayinclude one or more of trapping a first set of particulates in theexhaust flow at the inlet opening of the PM sensor, and guiding a secondset of particulates in the exhaust flow from the inlet towards a PMsensor element positioned at or near the second flow plate to facilitatedeposition of the second set of particulates onto the PM sensor element,the first set of particulates being larger than the second set ofparticulates. When a rate of deposition of the second set ofparticulates on the PM sensor element exceeds a threshold rate, a leakin a particulate filter located upstream of the PM sensor may beindicated. Herein, the first flow plate further guides the exhaust flowtowards the second flow plate and wherein the second flow plate furtherredirects the exhaust flow towards the outlet of the PM sensor.

The controller may perform a method 300 described below with referenceto FIG. 3 to adjust the PM sensor inlet opening based on the exhaustflow rate. Instructions for carrying out method 300 and the rest of themethods included herein may be executed by a controller (such ascontroller 12 shown in FIG. 1 and FIGS. 2A-2B) based on instructionsstored on a memory of the controller and in conjunction with signalsreceived from sensors of the engine system, such as the sensorsdescribed above with reference to FIGS. 1, 2A and 2B. The controller mayemploy engine actuators of the engine system to adjust engine operation,according to the methods described below.

FIG. 2C shows a schematic view 270 of a second embodiment of the PMsensor 201. The second embodiment is substantially similar to the firstembodiment described above with respect to FIGS. 2A and 2C. However, thesecond embodiment comprises a PM sensor element 254 oriented in adirection perpendicular to a direction of the PM sensor element 254 inthe first embodiment.

As shown, the PM sensor element 254 comprises interdigitated electrodes220 and heating element 218 located on opposite sides of the substrate216. The PM sensor element 254 is positioned between the first flowredirector 234 and the second flow redirector 236 such that the sensingportion of the PM sensor element extends parallel to the first flowredirector 234 and the second flow redirector 236. Herein, the sensingportion of the PM sensor element 254 is directed towards a directionparallel to the incoming exhaust flow 246, for example. The electrodes220 of the PM sensor element 254 are facing towards the top surface 212.Thus, the heating element 218 is facing towards the angled bottomportion 210 (towards the first flow redirector 234, for example). Inthis way, the PM sensor element 254 lies substantially in a horizontaldirection parallel to the x-axis with respect to a direction of gravity(arrow 299).

By doing this, a passage 262 is created between the electrodes 220 ofthe PM sensor element 254 and the second flow redirector 236. Exhaustgas from the space between the first flow redirector 234 and the secondflow redirector 236 flows through the passage 262 before flowing throughthe outlet 214. A width 264 of the passage is measured between a bottomsurface of the second flow redirector 236 and a top surface of theelectrodes 220. The width 264 may be a range between 0.1 to 0.2millimeters. In one example, the width is exactly 0.15 millimeters.Therefore, the PM sensor element 254 is closer to the second flowredirector 236 compared to the first flow redirector 234. Thus, an areafor exhaust gas to flow through between the second flow redirector 236and the PM sensor element 254 is reduced compared to the firstembodiment of FIGS. 2A and 2B. In this way, particulates (e.g., thesecond set of particulates 244) are more drawn by a charge of theelectrodes 220, which may promote particulate accumulation across a faceof the electrodes 220.

In one example, the electrodes 220 and heating element 218 may bepositioned on major surfaces of the substrate, meaning that they havegreater surface area than sides of the element (e.g., the surface areaof the cylindrical side surface). Thus, side surfaces of the substrate216 may as the surface portions of the substrate not including theelectrodes 220 or the heating element 218 and being a different surfacefrom those having the electrodes 220 or heating element 218. In thedepicted example, planes of the side surfaces are perpendicular toplanes of the major surfaces. Therefore, the planes of the majorsurfaces are parallel to incoming exhaust flow 246 whereas planes of theminor surfaces are perpendicular to incoming exhaust flow 246.

FIG. 2D shows a top view 280 of the PM sensor 201 comprising theprotection tube 250 and the interdigitated electrodes 220. The sidesurfaces of the substrate (e.g., substrate 216) are pressed againstinterior surfaces of the protection tube 250. The electrodes comprisepositive and negative ends corresponding to connecting wires 224 and 222respectively. Positive wire 224 is shown by a solid line and negativewire 222 is shown by a dashed line. As described above, the wires 222and 224 are spaced away from one another by some distance. As PMdeposits onto the electrodes 220, the PM may bridge wire 222 to wire224, indicating a degradation of an upstream particulate filter.

In this example, a majority of the wire 222 is arc-shaped originatingfrom a single linear wire of the wire 222. Likewise, a majority of thewire 224 is arc-shaped originated from a single linear wire of the wire222. The arcs of the wires 222 and 224 are longer in a radially outwarddirection such that arcs proximal to the protection tube 250 are longerthan arcs distal to the protection tube. The wire 222 and wire 224extend in opposite directions, alternating along a face of a substrate(e.g., substrate 216 of FIGS. 2A, 2B, and 2C). The wires 222 and 224depicted in the current embodiment may be used in the first embodimentof FIGS. 2A and 2B or the second embodiment of FIG. 2C.

Turning now to FIG. 3, a method 300 for adjusting the inlet opening of aPM sensor (such as a PM sensor 201 of FIGS. 1, 2A and 2B) based on anexhaust flow rate is described. Specifically, the amount of opening ofthe inlet to the PM sensor positioned in an exhaust flow may beincreased or decreased when the exhaust flow rate of the exhaust flowupstream of the particulate matter sensor is respectively higher orlower than the threshold.

At 302, method 300 includes determining and/or estimating engineoperating conditions. Engine operating conditions determined mayinclude, for example, engine speed, exhaust flow rate, enginetemperature, exhaust air-fuel ratio, exhaust temperature, duration (ordistance) elapsed since a last regeneration of the DPF, PM load on PMsensor, boost level, ambient conditions such as barometric pressure andambient temperature, etc.

The engine exhaust passage may include one or more sensors positionedupstream and/or downstream of the DPF for determining an exhaust flowrate. For example, the engine may include flow meters for exhaust massflow measurements and determining exhaust flow rate at the inlet of thePM sensor. In some examples, the incoming exhaust flow rate at the inletof the PM sensor may be determined based on an intake exhaust flow rate.Thus, in some examples, the exhaust gas flow rate through the exhaustpassage in which the PM sensor is installed may be estimated base onalternate engine sensors and/or operating conditions.

At 304, the method includes determining whether the exhaust flow rate ishigher than a threshold. In one example, the threshold may be athreshold rate based on a desired rate of deposition of the particulateson the particulate matter sensor element. In other examples, thethreshold may be based on a time to regeneration threshold of the PMsensor. Typically, when the incoming exhaust flow rate is high, the timeto reach regeneration threshold of the PM sensor is lower than when theexhaust flow rate is low.

If the exhaust flow rate is lower than the threshold, then method 300proceeds to 306, where the amount of opening of the PM sensor inlet isincreased. As discussed above with reference to FIGS. 2A-2B, the PMsensor may include a first flow redirector and a flow controller (suchas flow controller 238 shown in FIGS. 2A-2B) positioned at the inlet,where an end of the flow controller is positioned a distance away fromthe first flow redirector to generate a gap at the inlet. As such,increasing the amount of opening comprises increasing the gap betweenthe first flow redirector and the flow controller by rotating the flowcontroller in a first direction away from the first flow redirector at308. Rotating the flow controller in the first direction includessending signals to the motor actuator to rotate the hinge coupling theflow controller to the protection tube in a first direction for athreshold amount. In one example, the flow controller may be rotated 30°about a central axis of the PM sensor in an anti-clockwise. Increasingthe gap between the flow controller and the first flow redirector allowsmore exhaust to flow into the PM sensor, thereby increasing the amountof particulates flowing into the PM sensor which in turn increased therate of deposition of particulates on the PM sensor, for example.However, if the exhaust flow rate is higher than the threshold, thenmethod 300 proceeds to 310 where the amount of opening of the inlet isdecreased. As such, decreasing the amount of opening comprisesdecreasing the gap between the first flow redirector and the flowcontroller by rotating the flow controller in a second direction,opposite to the first direction, and away from the first flow redirectorat 312. Rotating the flow controller in the second direction includessending signals to the motor actuator to rotate the hinge coupling theflow controller to the protection tube in the second direction for athreshold amount. In one example, the flow controller may be rotated 30°about a central axis of the PM sensor in an anti-clockwise. Decreasingthe gap between the flow controller and the first flow redirectorrestricts the exhaust flowing into the PM sensor, thereby decreasing theamount of particulates and thereby decreasing the rate of deposition ofparticulates on the PM sensor, for example.

In one example, the opening is increased (at 306) or decreased (at 310)by rotating the flow controller by a threshold amount, the thresholdamount is a fixed amount which is further based on the exhaust flowrate. For example, when the exhaust flow rate is above the threshold,then the flow controller may be rotated by 30° in the second direction(at 312), however, if the exhaust is lower than the threshold, the flowrate controller may be rotated by 30° in the first direction (at 308).In other example, the flow rate controller may be rotated by a thresholdamount, wherein the threshold amount is variable and further based onthe exhaust flow rate. For example, at 312, if the exhaust flow rate isover the threshold by a certain amount, the amount of opening will bedecreased by a greater amount as the amount by which the exhaust flowrate above the threshold increases. Similarly, at 308, if the exhaustflow rate is below the threshold by a certain amount, the amount ofopening will be increased by a greater amount as the amount by which theexhaust flow rate below the threshold decreases. Said another way, theamount of opening may depend on the amount by which the exhaust flowrate differs from the threshold.

Once the inlet opening is adjusted based on the exhaust flow rate(either increased at 306 or decreased at 310), method 300 proceeds to314. At 314, particulates traveling in the exhaust flow may be separatedbased on size from the exhaust flow flowing to the PM sensor sensingelement. Larger particulates and/or water droplets may be trapped at afirst flow redirector (such as first flow redirector 234 shown in FIGS.2A-2B), for example, thereby allowing only the smaller particulates inthe exhaust to enter (e.g., pass through) the PM sensor inlet opening.These smaller particulates may then be directed towards the PM sensorelement as described in FIGS. 2A and 2B, and subsequently deposited onthe PM sensor element (e.g., sensor element 254 shown in FIGS. 2A-2B).

Next at 316, the method includes determining if PM sensor regenerationconditions are met. Specifically, when the PM load on the PM sensorelement is greater than a threshold, or when a resistance of the PMsensor drops to a threshold resistance, the PM sensor regenerationconditions may be considered met, and the PM sensor may need to beregenerated to enable further PM detection. If the PM sensorregeneration conditions are met, then method 300 proceeds to 320 wherethe PM sensor may be regenerated as described in method 400 of FIG. 4.However, if PM sensor regeneration conditions are not met when checkedat 316, then method 300 proceeds to 318, where the PM sensor continuesto collect PMs on the PM sensor. As such, any PMs not deposited on thePM sensor is directed out of the PM sensor via the outlet of the PMsensor.

Method 300 described above may be performed by a controller to maintainthe PM sensor deposition rate by adjusting the inlet opening of the PMsensor. In other embodiments, where the PM sensor includes a springhinge to couple the flow controller to the protection tube of the PMsensor, the adjusting of the PM sensor inlet opening may be achievedpassively without an intervention by the controller. Herein, based onthe pressure exerted by the incoming exhaust gas, the spring hinge mayrotate the flow controller, and thereby control the amount of opening atthe inlet of the PM sensor.

Thus, an example method includes adjusting an amount of opening of aninlet to a particulate matter sensor positioned in an exhaust flow inresponse to an exhaust flow rate of the exhaust flow upstream of theparticulate matter sensor. The adjusting includes increasing the amountof opening of the inlet when the exhaust flow rate falls below athreshold rate and further includes decreasing the amount of opening ofthe inlet when the exhaust flow rate exceeds the threshold rate. Theparticulate matter sensor includes a first flow redirector and a flowcontroller positioned at the inlet, where an end of the flow controlleris positioned a distance away from the first flow redirector to generatea gap at the inlet. Increasing the amount of opening includes increasingthe gap between the first flow redirector and the flow controller byrotating the flow controller in a first direction away from the firstflow redirector and decreasing the amount of opening comprisesdecreasing the gap between the first flow redirector and the flowcontroller by rotating the flow controller in a second direction,opposite the first direction, towards the first flow redirector. Theparticulate matter sensor further includes a second flow redirectorpositioned proximate to an outlet of the particulate matter sensor, thesecond flow redirector separated from the first flow redirector by adistance. The second flow redirector directs exhaust gases through theparticulate matter sensor and towards a particulate matter sensorelement positioned proximate to the outlet of the particulate mattersensor via the first flow redirector and the second flow redirector.

Turning now to FIG. 4, a method 400 for regenerating the PM sensor (suchas a PM sensor 106 shown at FIG. 1, for example) is shown. Specifically,when the soot load on the PM sensor is greater than the threshold, orwhen a resistance of the PM sensor adjusted for temperature drops to athreshold resistance, the PM sensor regeneration conditions may beconsidered met, and the PM sensor may need to be regenerated to enablefurther PM detection. At 402, regeneration of the PM sensor may beinitiated and the PM sensor may be regenerated by heating up the sensorat 404. The PM sensor may be heated by actuating a heating elementcoupled thermally to the sensor electrode surface, such as a heatingelement embedded in the sensor, until the soot load of the sensor hasbeen sufficiently reduced by oxidation of the carbon particles betweenthe electrodes. The PM sensor regeneration is typically controlled byusing timers and the timer may be set for a threshold duration at 402.Alternatively, the sensor regeneration may be controlled using atemperature measurement of the sensor tip, or by the control of power tothe heater, or any or all of these. When timer is used for PM sensorregeneration, then method 400 includes checking if the thresholdduration has elapsed at 406. If the threshold duration has not elapsed,then method 400 proceeds to 408 where the PM sensor regeneration may becontinued. If threshold duration has elapsed, then method 400 proceedsto 410 where the soot sensor regeneration may be terminated and theelectric circuit may be turned off at 412. Further, the sensorelectrodes may be cooled to the exhaust temperature for example. Method400 proceeds to 414 where the resistance between the electrodes of thesoot sensor is measured. From the measured resistance, possiblycompensated for temperature, the PM or soot load of the PM sensor (i.e.,the accumulated PMs or soot between the electrodes of the PM sensor) maybe calculated at 416 and the method proceeds to 418. At 418, thecalculated soot load of the PM sensor may be compared with a threshold,Lower_Thr. The threshold Lower_Thr, may be a lower threshold, lower thanthe regeneration threshold, for example, indicating that the electrodesare sufficiently clean of soot particles. In one example, the thresholdmay be a threshold below which regeneration may be terminated. If thesoot load continues to be greater than Lower_Thr, indicating thatfurther regeneration may be required, method 400 proceeds to 408 wherePM sensor regeneration may be repeated. However, if the PM sensorcontinues to undergo repeated regenerations, the controller may seterror codes to indicate that the PM sensor may be degraded or theheating element in the soot sensor may be degraded. If the soot load islower than the threshold Lower_Thr, indicating that the electrodesurface is clean, method 400 proceeds to 420, where the soot sensorresistance and regeneration history may be updated and stored in memory.For example, a frequency of PM sensor regeneration and/or an averageduration between sensor regenerations may be updated. At 422, variousmodels may then be used by the controller to calculate the percentageefficiency of the DPF the filtration of soot. In this way, the PM sensormay perform on-board diagnosis of the DPF.

FIG. 5 illustrates an example routine 500 for diagnosing DPF functionbased on the regeneration time of the PM sensor. At 502, it may becalculated by the controller, through calibration, the time ofregeneration for the PM sensor, t(i)_regen, which is the time measuredfrom end of previous regeneration to the start of current regenerationof the PM sensor. At 504, compare t(i)_regen to t(i−1)_regen, which isthe previously calibrated time of regeneration of the PM sensor. Fromthis, it may be inferred that the soot sensor may need to cycle throughregeneration multiple times in order to diagnose the DPF. If thet(i)_regen is less than half the value of t(i−1) region, then at 508indicate DPF is leaking, and DPF degradation signal is initiated.Alternatively, or additionally to the process mentioned above, the DPFmay be diagnosed using other parameters, such as exhaust temperature,engine speed/load, etc. The degradation signal may be initiated by, forexample, a malfunction indication light on diagnostic code.

A current regeneration time of less than half of the previousregeneration time may indicate that the time for electric circuit toreach the R_regen threshold is shorter, and thus the frequency ofregeneration is higher. Higher frequency of regeneration in the PMsensor may indicate that the outflowing exhaust gas is composed of ahigher amount of particulate matter than realized with a normallyfunctionally DPF. Thus, if the change of regeneration time in the sootsensor reaches threshold, t_regen, in which the current regenerationtime of the PM sensor is less than half of that of the previousregeneration time, a DPF degradation, or leaking, is indicated, forexample via a display to an operator, and/or via setting a flag storedin non-transitory memory coupled to the processor, which may be sent toa diagnostic tool coupled to the processor. If the change ofregeneration time in the soot sensor does not reach threshold t_regen,then at 506 DPF leaking is not indicated. In this way, leaks in aparticulate filter positioned upstream of the particulate matter sensormay be detected based on a rate of deposition of the particulates on theparticulate matter sensor element.

Turning now to FIG. 6, map 600 shows an example relationship between anexhaust flow rate, a PM sensor inlet opening, and a PM load on a PMsensor. The first plot 602 of 600 shows the exhaust flow rate asdetermined by a flow rate sensor positioned upstream of the PM sensor.The second plot 604 shows the PM sensor inlet opening as determined byrotating a flow controller positioned proximate to an inlet of the PMsensor as described in FIGS. 2A and 2B. The third plot 606 shows the PMload on the PM sensor. The dashed line 612 indicates the PM regenerationthreshold, while dashed line 614 indicates the Lower_Thr, indicatingthat the PM sensor electrodes are clean, as described in FIG. 4. Dashedlines 608 and 610 indicate threshold exhaust rate and threshold inletopening respectively. For each plot, time is depicted along the x(horizontal) axis while values of each respective parameter are depictedalong the y (vertical) axis.

At time t0, the PM sensor is relatively clean (plot 606) with low PMload lower than Lower_Thr (line 614) indicating that the PM sensor hasbeen regenerated recently. The exhaust flow rate (plot 602) is higherthan the threshold exhaust rate (line 608). When the exhaust rate ishigher than the threshold, the PM sensor inlet opening may be adjustedby adjusting a movable plate (such as flow controller 238 in FIGS. 2Aand 2B) to a final position between a first (closed) position and asecond (open) position. As such, the final position may be closer to thefirst position than the second position. Herein, the movable plate maybe adjusted by actuating a motor to rotate a hinge coupling the movableplate to the PM sensor in a first direction (anti-clockwise, forexample) towards a first flow redirector proximate to an inlet of the PMsensor. The technical effect of adjusting the PM sensor inlet opening tothe final position closer to the first close position, is that the gapbetween the movable plate and the first flow redirector is decreased,thereby decreasing the amount of PMs entering the PM sensor andsubsequently deposited on the PM sensor electrode. In this way, the PMsensor deposition rate may be maintained at a desired level. Herein, theslope of the line 606 indicates the rate of deposition of PMs on the PMsensor electrode.

Between t0 and t1, the exhaust flow (plot 602) continues to remainhigher than the threshold exhaust rate (line 608), as a result, the PMsensor inlet opening is maintained closer to the first closed position.During the time between t0 and t1, the PM sensor continues to collectparticulates at a constant rate indicated by line 606.

At t1, the PM load on the PM sensor reaches the threshold forregeneration (dashed line 612). During the time between t1 and t2, PMsensor may be regenerated. A controller may have instructions to send aregeneration signal to a regeneration circuit, responsive to the PMlevel data. Regenerating the PM sensor includes operating theregeneration portion of the electric circuit for a threshold time and/orthreshold duration as described in FIG. 4 to burn off the PMs depositedbetween the electrodes of the PM sensor, for example.

At t2, the PM sensor is relatively clean indicated by low PM load (plot606). However, the exhaust flow rate (plot 602) falls below thethreshold rate (line 608) at time t2. Between t2 and t3, when theexhaust rate is lower than the threshold, the PM sensor inlet openingmay be adjusted by adjusting a movable plate (such as flow controller238 in FIGS. 2A and 2B) to a final position closer to the secondposition than the first position (plot 604). Herein, the movable platemay be adjusted by actuating a motor to rotate a hinge coupling themovable plate to the PM sensor in a second direction (clockwise, forexample) away from the first flow redirector proximate to the inlet ofthe PM sensor. The technical effect of adjusting the PM sensor inletopening to the final position closer to the second open position, isthat the gap between the movable plate and the first flow redirector isincreased, thereby increasing the amount of PMs entering the PM sensorand subsequently deposited on the PM sensor electrode. In this way, thePM sensor deposition rate may be maintained at the desired levelindicated by the slope of line 606. As such the slope of the line 606between t2 and t4 is similar to the slope of the line 606 between t0 andt1. In this way, by adjusting the inlet opening based on the exhaustflow rate, the PM sensor loading may be maintained at a constant rate.

Between t3 and t4, the exhaust flow rate (plot 602) rises about thethreshold rate (line 608). By adjusting the PM sensor inlet opening to afinal position closer to a first close position as explained earlier,the PM sensor loading is maintained at the desired rate (slope of line606). In a similar way, when the exhaust flow rises about the thresholdbetween t4 and t5, the PM sensor inlet opening is adjusted to a finalposition closer to the second open position. By actively adjusting theinlet opening based on the exhaust flow rate, the PM sensor loading maybe maintained at the desired level. In this way, the PM sensorsensitivity may become independent of the exhaust flow rate.

Again at t5, the PM load (plot 606) reaches the regeneration threshold(dashed line 612). Hence between t5 and t6, the PM sensor may beregenerated as explained earlier. At t6, the PM sensor is relativelyclean. Furthermore, the PM sensor inlet opening is adjusted to a finalposition closer to the second open position as the exhaust flow (plot602) remains higher than the threshold (line 608). However, irrespectiveof actively adjusting the PM sensor inlet opening, the PM load on the PMsensor (plot 606) increases sharply, indicating that the rate ofdeposition of particulates on the PM sensor is higher than the desireddeposition rate, indicating that the DPF located upstream of the PMsensor is leaking. Thus, in response to a current rate of deposition ofparticulates on the PM sensor rising above a desired rate of depositionof particulates on the PM sensor, DPF leaks may be determined and adiagnostic code may be set. For example, an MIL may be set indicatingthat the DPF needs to be replaced. By virtue of the PM sensor beingindependent of the exhaust rate, DPF leakage may be detected in a timelymanner, thereby reducing the possibility of operating the engine with aleaking particulate filter and thus reducing soot particle emission inthe exhaust.

In this way, by adjusting the inlet opening based on the exhaust flowrate, the PM sensor loading may be maintained at a constant rate and thedependence of PM sensor sensitivity on exhaust flow rate may be furtherreduced. Thus, the technical effect of increasing the PM sensor inletopening when the exhaust flow rate falls below the threshold anddecreasing the opening when the exhaust flow rate rises above thethreshold is that the rate of deposition of particulates on the PMsensor electrodes remain near constant. The PM sensor sensitivity isindependent of the incoming exhaust flow rate, thereby measuring PMsexiting the DPF more accurately and reliably. Thus, any leaks ordegradation of the DPF may be detected more efficiently and effectively.

The systems and methods described above also provide for a method ofparticulate matter sensing, in an exhaust system, the method comprisingadjusting an amount of opening of an inlet to a particulate mattersensor positioned in an exhaust flow in response to an exhaust flow rateof the exhaust flow upstream of the particulate matter sensor, theparticulate matter sensor element oriented with its major surfaceparallel to a direction of exhaust flow. In a first example of themethod, the method may additionally or alternatively include wherein theadjusting includes increasing the amount of opening of the inlet whenthe exhaust flow rate falls below a threshold rate and further includesdecreasing the amount of opening of the inlet when the exhaust flow rateexceeds the threshold rate. A second example of the method optionallyincludes the first example, and further includes wherein the particulatematter sensor includes a first flow redirector and a flow controllerpositioned at the inlet, where an end of the flow controller ispositioned a distance away from the first flow redirector to generate agap at the inlet. A third example of the method optionally includes oneor more of the first and the second examples, and further includeswherein the increasing the amount of opening comprises increasing thegap between the first flow redirector and the flow controller byrotating the flow controller in a first direction away from the firstflow redirector. A fourth example of the method optionally includes oneor more of the first through the third examples, and further includeswherein the decreasing the amount of opening comprises decreasing thegap between the first flow redirector and the flow controller byrotating the flow controller in a second direction, opposite the firstdirection, towards the first flow redirector. A fifth example of themethod optionally includes one or more of the first through the fourthexamples, and further includes wherein the particulate matter sensorfurther includes a second flow redirector positioned proximate to anoutlet of the particulate matter sensor, the second flow redirectorseparated from the first flow redirector by a distance. A sixth exampleof the method optionally includes one or more of the first through thefifth examples, and further comprising directing exhaust gases throughthe particulate matter sensor and towards a particulate matter sensorelement positioned proximate to the outlet of the particulate mattersensor via the first flow redirector and the second flow redirector,where the particulate matter sensor element is oriented in a directionparallel to the first and second flow redirectors. A seventh example ofthe method optionally includes one or more of the first through thesixth examples, and further including detecting leaks in a particulatefilter positioned upstream of the particulate matter sensor andindicating degradation of the particulate filter based on a rate ofdeposition of the particulates on the particulate matter sensor element.An eighth example of the method optionally includes one or more of thefirst through the seventh examples, and further wherein the thresholdrate is based on a desired rate of deposition of the particulates on theparticulate matter sensor element.

The systems and methods described above also provide for a method ofparticulate matter sensing, in a particulate matter sensor system, themethod comprising increasing exhaust flow to a PM sensor elementpositioned inside the PM sensor, where the PM sensor is positioned in anexhaust flow passage, the PM sensor element oriented with its majorsurface parallel to a direction of exhaust flow, responsive to anexhaust flow rate of exhaust flow in the exhaust flow passage beinglower than a threshold and decreasing the exhaust flow to the PM sensorelement responsive to the exhaust flow rate being higher than thethreshold. In a first example of the method, the method may additionallyor alternatively include wherein the increasing exhaust flow includesrotating a flow rate controller located proximate to an inlet opening ofthe PM sensor in a first direction and wherein the decreasing theexhaust flow includes rotating the flow rate controller in a seconddirection, opposite the first direction. A second example of the methodoptionally includes the first example, and further includes wherein therotating the flow controller in the first direction further includesmoving the flow rate controller away from a first flow plate positionedat or near the inlet opening of the PM sensor, and wherein the rotatingthe flow controller in the second direction further includes moving theflow rate controller towards the first flow plate of the PM sensorassembly. A third example of the method optionally includes one or moreof the first and the second examples, and further includes wherein thePM sensor further comprises a second flow plate located proximate to anoutlet of the PM sensor, and wherein the second flow plate is separatedfrom the first flow plate by a distance. A fourth example of the methodoptionally includes one or more of the first through the third examples,and further includes trapping a first set of particulates in the exhaustflow at the inlet opening of the PM sensor and guiding a second set ofparticulates in the exhaust flow from the inlet towards a PM sensorelement positioned at or near the second flow plate to facilitatedeposition of the second set of particulates onto the PM sensor element,the first set of particulates being larger than the second set ofparticulates. A fifth example of the method optionally includes one ormore of the first through the fourth examples, and further comprisingindicating a leak in a particulate filter located upstream of the PMsensor when a rate of deposition of the second set of particulates onthe PM sensor element exceeds a threshold rate. A sixth example of themethod optionally includes one or more of the first through the thirdexamples, and further includes wherein the first flow plate furtherguides the exhaust flow towards the second flow plate and wherein thesecond flow plate further redirects the exhaust flow towards the outletof the PM sensor.

The systems and methods described above also provide for a particulatematter sensor comprising a first flow redirector proximate to an inletof the PM sensor, a second flow redirector proximate to an outlet of thePM sensor, the second flow redirector separated from the first flowredirector by a distance, a PM sensor element parallel to the first andsecond flow redirectors, where at least a portion of the PM sensorelement is positioned between the first flow redirector and the secondflow redirector, and a movable plate positioned at or near the inlet ofthe PM sensor adapted to adjust an inlet opening of the inlet. In afirst example of the particulate matter sensor, the sensor mayadditionally or alternatively include a controller withcomputer-readable instructions stored on non-transitory memory foradjusting the movable plate into a final position at or between a firstposition having a smaller amount of inlet opening and a second positionhaving a larger amount of inlet opening based on an exhaust flow rate ofexhaust gas upstream of the PM sensor. A second example of theparticulate matter sensor optionally includes the first example andfurther wherein adjusting the movable plate into the final positionincludes adjusting the movable plate closer to the first position thanthe second position as the exhaust flow rate increases and furtherincludes adjusting the flow controller closer to the second positionthan the first position as the exhaust flow rate decreases. A thirdexample of the particulate matter sensor optionally includes one or moreof the first and the second examples, and further includes instructionsfor indicating a leak in a particulate filter located upstream of the PMsensor when a current rate of deposition of particulates on the PMsensor exceeds a desired rate of deposition of particulates on the PMsensor

Note that the example control and estimation routines included hereincan be used with various engine and/or vehicle system configurations.The control methods and routines disclosed herein may be stored asexecutable instructions in non-transitory memory and may be carried outby the control system including the controller in combination with thevarious sensors, actuators, and other engine hardware. The specificroutines described herein may represent one or more of any number ofprocessing strategies such as event-driven, interrupt-driven,multi-tasking, multi-threading, and the like. As such, various actions,operations, and/or functions illustrated may be performed in thesequence illustrated, in parallel, or in some cases omitted. Likewise,the order of processing is not necessarily required to achieve thefeatures and advantages of the example embodiments described herein, butis provided for ease of illustration and description. One or more of theillustrated actions, operations and/or functions may be repeatedlyperformed depending on the particular strategy being used. Further, thedescribed actions, operations and/or functions may graphically representcode to be programmed into non-transitory memory of the computerreadable storage medium in the engine control system, where thedescribed actions are carried out by executing the instructions in asystem including the various engine hardware components in combinationwith the electronic controller.

It will be appreciated that the configurations and routines disclosedherein are exemplary in nature, and that these specific embodiments arenot to be considered in a limiting sense, because numerous variationsare possible. For example, the above technology can be applied to V-6,I-4, I-6, V-12, opposed 4, and other engine types. The subject matter ofthe present disclosure includes all novel and non-obvious combinationsand sub-combinations of the various systems and configurations, andother features, functions, and/or properties disclosed herein.

The following claims particularly point out certain combinations andsub-combinations regarded as novel and non-obvious. These claims mayrefer to “an” element or “a first” element or the equivalent thereof.Such claims should be understood to include incorporation of one or moresuch elements, neither requiring nor excluding two or more suchelements. Other combinations and sub-combinations of the disclosedfeatures, functions, elements, and/or properties may be claimed throughamendment of the present claims or through presentation of new claims inthis or a related application. Such claims, whether broader, narrower,equal, or different in scope to the original claims, also are regardedas included within the subject matter of the present disclosure.

The invention claimed is:
 1. A method for a particulate matter (PM)sensor, comprising: increasing exhaust flow to a PM sensor elementpositioned inside the PM sensor, where the PM sensor is positioned in anexhaust flow passage, responsive to an exhaust flow rate of exhaust flowin the exhaust flow passage being lower than a threshold; and decreasingthe exhaust flow to the PM sensor element responsive to the exhaust flowrate being higher than the threshold, the PM sensor element orientedwith its major surface parallel to a direction of exhaust flow, whereinthe increasing and decreasing of the exhaust flow includes rotating aflow rate controller located proximate to an inlet opening of the PMsensor, wherein the rotating the flow rate controller in a firstdirection further includes moving the flow rate controller away from afirst flow plate positioned at or near the inlet opening of the PMsensor, and wherein the rotating the flow rate controller in a seconddirection further includes moving the flow rate controller towards thefirst flow plate of the PM sensor.
 2. The method of claim 1, wherein thePM sensor further comprises a second flow plate located proximate to anoutlet of the PM sensor, and wherein the second flow plate is separatedfrom the first flow plate by a distance, and where the PM sensor elementis located in the distance parallel to the first and second flow plates,proximate to the second flow plate.
 3. The method of claim 2, furthercomprising: trapping a first set of particulates in the exhaust flow atthe inlet opening of the PM sensor; and guiding a second set ofparticulates in the exhaust flow from the inlet opening towards the PMsensor element positioned at or near and parallel to the second flowplate to facilitate deposition of the second set of particulates ontothe PM sensor element, the first set of particulates being larger thanthe second set of particulates.
 4. The method of claim 3, furthercomprising indicating a leak in a particulate filter located upstream ofthe PM sensor when a rate of deposition of the second set ofparticulates on the PM sensor element exceeds a threshold rate.
 5. Themethod of claim 4, wherein the first flow plate further guides theexhaust flow towards the second flow plate and wherein the second flowplate further redirects the exhaust flow towards the outlet of the PMsensor.